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1. 3 19 Filter Element R placement titane t 3 21 e LE ENTE cue Dav SR HH a eh eae aed 3 22 Capacitor 3 23 Heat Sink Component Replacement siennes 3 24 Section 4 Parts List Power Supply a e a r a 4 2 Interior Right a nn a 4 3 Back Interior Right Sides 2 4 4 Interior FAR SIG mE 4 5 TEE 4 6 Recommended Spare Parts teg rece ens 4 7 Section 5 Parts List Torch and Consumables TOO Hand TorchiAssembly iiie rore E edis antenne 5 2 TOOM Machine Torch Assembly un a etos qat redet ae ene 5 4 Torch Consumable Configurations eene nennen nens entren entres 5 6 Recommended Spare Parts aient cc ako pa FEE E ere FERE E EO LEER ee 5 7 Section 6 Wiring Diagrams Electrical esee EE EU RM 6 2 iv powermax10
2. OF D 5 i cons m 4 2 lt veus 022 2 1 TN H 40 POSITION RIBBON CABLE T n li m lt a 7 GAS i Y T 1 STATUS 45 50 60 65 70 75 80 85 2 CN by O O O O OO 0 0 0 m w O E s lt WW 1 uas OW 1 deg 55 ue lt VACR saa a VW cow Vv gt See 38 D 009994 E 80 AMP UNIT 60 AMP UNIT TPI lt 087000 DOMESTIC 087007 CE 083169 DOMESTIC 083170 CE Lu lt MEAT INPUT VOLTAGE 200 600vac 230 400vac 200 600vac 230 400vac MINE D EUR OR TR ee te oe E f e J 1 3PH 3PH 1 3 PH 3PH Vbus Vac lt 540vac 750 750 750 750 PES ANS AA in mds 2 Vbus Vac gt 541vac 1 41 X Vac NA 1 41 X Vac NA Ec SE ran E CORD 129652 129653 129652 129726 WIRE GROUP 123607 129683 129732 129739 MACHINE INTERFACE CABLE 123603 123603 123603 123603 POWER SWITCH 51 003206 003206 005257 005257 NOTES FILTER PCB1 NA 041660 NA 041773 1 PIN 6 IS KEYING FEATURE ON 60A 2 PIN 9 IS LOCKOUT FEATURE POWER BD PCB2 041667 041667 041746 041746 CONTROL BD PCB3 041663 041707 041709 041710 aU xs aA 1 E lanpocs 0 cs mca TEMP SENSOR BD PCB4 041723 041723 041713 041713 UY Yeu Gaus TIMING DIAGRAM 013341 013341 013341 013341 Box 5010 Hanover
3. E Ses ome LS d ur m tes T 1 1 m 1 gt 29 a eee i I lt N INSTALL JUMPER 108056 CE UNITS ONLY 7 4 gt A 1 3er RM gt 0424 1 DIODES CONTROL BD sw n 5 DIAGNOSTIC LED S jax mi pl gt COE M mM ERES ARI RUE 1 10922 current INDUCTOR START START SIGNAL VALID gt SM NER aoe 0e ee sre s lol er 1 gt o ours i XFR 1 TRANSFER 15 ug TER SA EDT S RE META 1 k SELF DIAGNOSTICS FAILURE os NORMAL BLINKING 1 SEC RATE lt sav J 109109 009883 CURRENT ERE ET USE UT EE ORO 1 i DOM SOUGE INVERTER INTERLOCK VISIBLE FOR 10 SEC AFTER EVENT lt ma iri ees 4 E To TORCH STUCK OPEN s lt 10 VISIBLE FOR 10 SEC AFTER EVENT a bea 1 LI n a_r E Ls wo SP SPARE
4. Indicator LEDs Green Power ON LED When illuminated indicates that power is applied to system and power switch is ON 1 Gas Pressure LED Yellow When flashing indicates that the gas pressure is below 60 psig 4 1 bar for cutting or 40 psig 2 8 bar for gouging Green When illuminated indicates acceptable gas pressure for torch operation Yellow Torch Cap LED When illuminated indicates that the retaining cap is loose or not installed NOTE Turn power OFF correct this fault condition then turn power ON to extinguish LED Yellow Temp LED When illuminated indicates that the power supply temperature is too hot Red Fault LED When illuminated indicates that a fault condition exists which prevents system operation Yellow Low Line Voltage LED When illuminated indicates that line voltage is below 170 VAC or above 680 VAC On CE units it can also indicate a missing phase powermax1000 Service Manual MAINTENANCE Theory of Operation General Refer to Functional Description Sequence of Operation and the system wiring diagram in Section 6 Functional Description AC power enters the system through the power switch S1 to the input diode bridge D24 The voltage from the diode bridge supplies the Power Factor Correction PFC Boost Converter which provides a 750 VDC bus voltage The bus voltage then supplies the inverter and the flyback system power supply DC to DC converter on the power board PCB2 The power bo
5. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting in stallation may be considered for special ap plications Hypertherm Plasma Systems WARRANTY WARNING Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty WARNING You are responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment GENERAL Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship if Hypertherm is notified of a defect i with respect to the power supply within a period of two 2 years from the date of its delivery to you with the exception of G3 Series power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall
6. Connect gas supply to filter on power unit Connect work lead to work piece Apply power at line voltage disconnect box e Set ON OFF switch 51 to ON I Power ON lamp illuminates and Gas Pressure LED illuminates green indicating system is ready for operation Fault LEDs should not be illuminated see Troubleshooting for more information Turn current adjustment knob counterclockwise to gas test position Check air pressure setting Gas solenoid valve V1 opens to purge system and to allow setting of pressure Set gas pressure see Setup section in Operator Manual Set power switch S1 to OFF 0 Gas solenoid valve V1 closes Gas flow stops Arc extinguishes Post flow continues for 10 seconds Move torch to make cut Work piece falls away after cut Release plasma start switch on hand torch or remote start switch for machine torch Gas solenoid valve V1 opens Gas flow starts Cuting arc starts Position torch on work piece Depress plasma start switch on hand torch or remote start switch for machine torch e Select desired cutting amps with current adjustment knob Gas solenoid valve V1 closes gt Power circuits are read Gas flow stops 3 4 powermax1000 Service Manual TROUBLESHOOTING MAINTENANCE The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply theory In addition to being technically qualified
7. Internal 3 6 aie ee ee 3 7 Troubleshooting Guide iii 3 9 Voltage i ei ln T 3 13 Component Replacement sise 3 18 Power Cord Replacement D 3 18 IMStANALAION EE 3 19 litigio isle eur m 3 21 Work Cable Replacement iii 3 22 Capacitor Replacement iid ione te ele Fe ce c ERE EL edet evened c HER eu e eae 3 23 Heat Sink Component 21 0 11 eene nennen nnns en nnns enne nennen 3 24 powermax1000 Service Manual 3 1 MAINTENANCE Controls and Indicators Current Amps Adjustment Knob Indicator LEDs ON I OFF 0 Switch S1 JL Mode Switch E LT Pressure LH Gauge Pressure Regulator
8. France 15 Impasse des Rosiers 95610 Eragny France 0805 050 111 Tel 0805 050 222 Fax Hypertherm S r L Via Torino 2 20123 Milano Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 46 314 Technical Service Hypertherm B V Burg Haverkampstraat 13 7091 CN Dinxperlo Nederland 31 315 655866 Tel 31 315 655886 Fax Hypertherm B V 80 Vaartveld 9 4704 SE Roosendaal Nederland 00 800 49 73 7843 toll free in Europa 31 165 596900 Tel 31 165 596901 Fax ELECTROMAGNETIC COMPATIBILITY EMC EMC INTRODUCTION Hypertherm s CE marked equipment is built in compliance with standard EN50199 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN50199 may not be adequate to completely eliminate interfer ence when the affected equipment is in close proximity or has a high degree of sen sitivity such cases it may be necessary to use other measures to further reduce inter ference This plasma equipment is designed for use only in an industrial environment INSTALLATION AND USE The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electro magnetic disturbances are detected then it shall be the responsibility of the user to re solve the situation with the technical assis tance of the manufacturer In some cases this remedial action may be
9. 3 A Plasma Arc Can Cause Injury and 1 4 Arc Rays Can Burn Eyes and rere de fate p age o RR a Ro Re regentes 1 4 Grounding Safety Eana 1 4 Compressed Gas Equipment Safety ret retta irn aaa aE na te aya ta lat x era a v tee 1 5 Gas Cylinders Can Explode If Damaged i tente sitter ceret taedia 1 5 Noise Can Damage 1 5 Pacemaker and Hearing Ald Operation eu Ue ec nic PERSEO CERRAR dle 1 5 A Plasma Arc Can Damage Frozen Pipes cerro ret esee tr eaves 1 5 Additional Safety Information Sustee e A Ex anas ed a etes ERR Reese La Esp a Fax inter late 1 5 Warming e m 1 6 Section 1a S curit Identifier les consignes de s curit iii 1a 2 Suivre les instructions de S CUrit eee cere pe tities ER Do Pe FUE E 1a 2 Danger Avertissement PEI CAaUtlOll sn tre rtm tera see eret cadet 1a 2 Le coupage peut provoquer un incendie ou une explosion iii 1a 2 Pr vention des incendies Pr vention des explosions 1a 2 Risque d explosion argon hydrog ne et m thane sie 1a 2 D tonation de l hy
10. BighE SIJE 4 3 Back Interior RIQhtSi0 4 4 Interior Fan Side ep 4 5 Heat Sink ASS mbly p A Le ie dires 4 6 Recommended Spare Parts deterrere nisiodo tegere tite ler vu ax ep ceeded eet etapa aa deena 4 7 powermax1000 Service Manual 4 1 PARTS POWER SUPPLY Power Supply Exterior Part Item Number Description Designator Qty 128686 Label Kit Domestic 1 128685 Label Kit CE 1 1 128689 Front end panel Domestic 1 128687 Front end panel CE 1 2 008965 Current adjustment knob 1 3 128630 End cap screws 8 4 123645 Ground clamp 1 5 011096 Regulator knob 1 6 128629 Cover screws 12 7 128690 Power supply cover with labels Domestic 1 128688 Power supply cover with labels CE 1 8 128626 Rear end panel 1 4 2 powermax1000 Service Manual Power Supply Interior Right Side Part ltem Number 128701 128702 128659 128623 128699 128622 128628 046116 108211 128662 128695 123602 O1 BR Description Control PCB assembly Domestic Control PCB assembly CE Pressure Transducer Pressure Regulator Pilot Arc IGBT Gate Drive Cable Gas Manifold ETR Box Tubing 8mm OD 6mm ID nylon On Off Knob Machine interface Power PCB Gate Drive Cables powermax1000 Service Manual PARTS POW
11. Lead Replacement Kit 35 ft 10 7 Torch Lead Replacement Kit 50 ft 15 2 m Torch Lead Replacement Kit ETR Repair Kit Regional Repair Centers only Torch Mounting Kit for reassembly after installation Quantity mE eek cA Top assembly includes the following consumables See page 4 3 for details of consumable parts 120926 120925 120928 120929 120931 Electrode Swirl Ring Retaining Cap Shield Nozzle ol powermax1000 Service Manual PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 5 PARTS TORCH AND CONSUMABLES Torch Consumable Configurations Hand Held Shielded 40A O Ring 058519 60A 120929 120928 120931 mor D 375a i 120926 120925 Gouging i 60A 120977 120928 220059 i Unshielded 40A 0 TUN EE i 120979 j S O Ring 60A id i 058519 0 120979 120928 220007 ss 1 z Mechanized Shielded 120926 120925 40 In CE countries unshielded 60A consumables may only be used in mechanized torch applications 120930 120928 120931 5 6 powermax1000 Service Manual PARTS TORCH AND CONSUMABLES Recommended Spare Parts Part Number 058519 027055 128644 128638 075586 002244 027254 128642 128564 128640 128521 027889 128639 075571 020620 120668 075004 087001 087
12. REDUCING EMISSIONS Mains Supply Cutting equipment must be connected to the mains supply according to the manufactur ers recommendations If interference oc curs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic con duit or equivalent Shielding should be elec trically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of Cutting Equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equip ment is in operation The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particu lar the spark gaps of arc striking and stabi lizing devices should be adjusted and main tained according to the manufacturer s recommendations Cutting Cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the cutting installation and adjacent to it sh
13. as simple as earthing the cutting circuit see Earthing of Workpiece other cases it could involve constructing an electromagnetic screen en closing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome ASSESSMENT OF AREA Before installing the equipment the user shall make an assessment of potential elec tromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables sig nalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hear ing aids f Equipment used for calibration or mea surement g Immunity of other equipment in the en vironment User shall ensure that other equipment being used in the environment is compatible This may require additional pro tection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be con sidered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises METHODS OF
14. be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm PATENT INDEMNITY Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will
15. in the work area Before operating read and understand the manufacturer s instruc tions and know your employer s safety practices Electric shock can kill Do not touch live electrical parts Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from clothing Keep gloves shoes clothing work area torch and this machinery dry to the state of California to cause birth defects and in some cases cancer Heat splatter and sparks cause fire and burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Explosion will result if pressurized containers are cut Arc rays can injure eyes and burn skin Wear correct eye and body protection Pilot arc can cause burns Keep the torch nozzle away from yourself and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS AVERTISSEMENT AMOR AGE INSTANTAN L arc s amorce aussit t qu on enclenche l interrupteur de la torche Noise can damage hearing Wear correct ear protection A A DO NOT REMOVE THIS MARKI
16. technicians must perform all testing with safety in mind If questions or problems arise during servicing call the nearest Hypertherm Technical Services Department listed in the front of this manual Test Equipment Multimeter Troubleshooting Procedures and Sequence When performing the troubleshooting procedures Refer to Section 6 for the system wiring diagram Refer to Section 4 to locate power supply components Refer to Section 5 for torch components After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power supply for proper operation Visual Inspection External Power OFF amp a Disconnected E Y Visual Inspection External Y Visual Inspection Internal Y Resistance Checks Power ON Y Troubleshooting Guide Y Voltage Checks 1 Inspect the outside of the power supply for damage to the cover and external components 2 Inspect the torch and the torch lead for damage powermax1000 Service Manual MAINTENANCE WARNING ELECTRIC SHOCK CAN KILL Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply If the power supply is directly connected to a line disconnect box switch the line disconnect to OFF O In the U S use a lock out tag out procedure until the service or maintenance work i
17. 00 Service Manual Section 1 SAFETY In this section Recognize Safety Information issues 1 2 Follow Safety Instructions usines 1 2 Cutting Can Cause Fire or Explosion sise 1 2 1 3 Cutting Can Produce Toxic 1 3 A Plasma Arc Can Cause Injury and Burns iii 1 4 Arc Rays Can Burn Eyes and 1 4 Grounding Safety 5 nean rae cater el ae ene 1 4 Compressed Gas Equipment Safety siennes 1 5 Gas Cylinders Can Explode If Damaged sisi 1 5 Noise Car Damage Hearing nite e hi ee rece ten int nets 1 5 Pacemaker and Hearing Aid Operation nennen nnne enne nnne nnns entren nennen 1 5 A Plasma Arc Can Damage Frozen Pipes iii 1 5 Additional Safety 1 5 Warning Label sasasi iia an 1 6 Hypertherm Plasma Systems 1 1 SAFETY RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard ga FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety la
18. 002 128637 128636 087003 087004 087005 087006 128634 128633 128635 128641 128643 128645 Description Torch O Ring Silicone Lubricant 1 4 Oz Tube T60 T80 Torch Handle Replacement Kit ETR Connector Replacement Kit Regional Repair Centers only T60 T80 Torch Handle Screw 5 required T60 T80 Torch Trigger Assembly with Spring Replacement Trigger Spring T60 T80 T60 T80 Start Switch Replacement Kit T60 T80 Hand Torch Main Body Replacement Kit T60M T80M Machine Torch Main Body Replacement Kit T60 T80 T60M T80M Torch Head Repair Retaining Clip T60 T80 T60M T80M Torch Cap Sensor Replacement Cap off Sensor Screws Torch Positioning Sleeve 32 Pitch 10 Inches Rack Standard Torch Positioning Sleeve without Rack 1 3 8 Inches Diameter Torch Mounting Screws T60 T80 Hand Torch Assembly with 25 ft 7 6 m Lead T60 T80 Hand Torch Assembly with 50 ft 15 2 m Lead T60 T80 Hand Torch Replacement Lead 25 ft 7 6 m T60 T80 Hand Torch Replacement Lead 50 ft 15 2 m T60M T80M Machine Torch Assembly with 15 ft 4 6 m Lead T60M T80M Machine Torch Assembly with 25 ft 7 6 m Lead T60M T80M Machine Torch Assembly with 35 ft 10 7 m Lead T60M T80M Machine Torch Assembly with 50 ft 15 2 m Lead T60M T80M Machine Torch Replacement Lead 15 ft 4 6 m T60M T80M Machine Torch Replacement Lead 25 ft 7 6 m T60M T80M Machine Torch Replacement Lead 35 ft 10 7 m T60M T80M Machine Torch Replacement Lead 50 ft 15 2 m T60M T80M Mounting Sle
19. ER SUPPLY Designator Qty PCB3 PCB3 b R 3 ft PCB2 worn PARTS POWER SUPPLY Power Supply Back Interior Right Side Part Item Number Description Designator Qty 1 128665 Strain relief arc voltage 1 2 128672 Power switch 51 1 3 128706 EMI Filter PCB CE only PCB1 1 4 128666 Power cable Domestic 3PH 1 128705 Power cable CE 3PH 1 4 4 powermax1000 Service Manual Power Supply Interior Fan Side PARTS POWER SUPPLY a Part Item Number 1 128627 011093 011094 128707 128693 128691 128692 128694 O1 W D Description Filter bowl Air filter element O ring Fan subassembly Inductor input choke Capacitor Power transformer Inductor output choke powermax1000 Service Manual Designator Mi L2 T2 L1 Qty PARTS POWER SUPPLY Power Supply Hea
20. MARK The 5 mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock The hand torches must have shielded consumable parts to maintain S mark compliance IEC Symbols Used The following symbols may appear on the power supply data plate control labels and switches Direct Current DC An inverter based power source e Alternating current AC Plasma torch in the TEST 2 position cooling and cutting A gas exiting nozzle D Plasma torch cutting and gouging Power is on AC input power connection O Power is off The terminal for the external Volt amp curve drooping protective earth conductor characteristic 2 6 powermax1000 Service Manual Section 3 MAINTENANCE In this section Controls and Indicators A tua 3 2 Theory Of Operation drain tante tent age idee gra PR 3 3 Cic iin er cece Rae 3 3 F nctional Descriptio essaies 3 3 Sequence of Operation ERES 3 4 Piete ce nei REM E DTE LU LIP 3 5 Test QUIPM NT 3 5 Troubleshooting Procedures and 9 3 5 Visual Inspection Extena 3 5 Visual Inspection
21. NG WARNING INSTANT START Arc starts instantly after torch switch is depressed 1a 6 2 12 01 1 1 1 2 Les tincelles produites par le coupage peuvent provoquer une explosion ou un incendie Pendant le coupage loigner toute mati re inflammable Conserver un extincteur a proximit et s assurer qu une personne soit pr te a l utiliser Ne jamais couper de r cipients ferm s L arc plasma peut provoquer des blessures et des br lures Couper l alimentation avant de d monter la torche Ne pas tenir la surface couper pr s de la trajectoire de coupe Porter des v tements de protection couvrant tout le corps Un choc lectrique caus par la torche ou les c bles peut tre fatal Se prot ger contre les risques de chocs lectriques Porter des gants isolants Ne pas porter de gants mouill s ou abim s S isoler de la surface de travail et du sol D brancher la prise ou la source de courant avant de manipuler l quipement L inhalation des vapeurs produites par le coupage peut tre dangereuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles
22. NH 03755 5010 603 643 3441 UNLESS OTHERWISE SPECIFIED DESCRIPTION DIMENSIONS ARE IN INCHES ELEC SCHEM 60 80A SYS CONTAINED THEREON IS CONSIDERED 3PLDECMAL 05 PROPRIETARY AND MAY NOT BE USED FRACTIONS 1 64 013342 013342 1 1 10F1 FOR MANUFACTURING OR FABRICATION ANGULAR PURPOSES WITHOUT PERMISSION PARTMUSTEE FEE OF BUNS MD SANE DRAWN BY DATE APPROVED BY DATE FROM INC WITH CHAMFER OR RADIUS 015 MWW 5 11 01 REVISIONS REV ECN DATE DRAWN DATE APPROVED A 11948 1 26 01 MWW B 12637 11201 LMB 11 5 01 DMB 2
23. SURES OU DES BR LURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux ou encore masque de soudure avec des verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc Puissance des verres teint s Courant de l arc 5 AWS E U ISO 4850 Jusqu 100 A N 8 NO 11 100 200 A N 10 NO 11 12 200 400 A NO 12 N 13 Plus de 400A N 14 14 Protection dela peau Porter des v tements de s curit pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant LES RAYONS DE L ARC PEUVENT BR LER LES YEUX ET LA PEAU Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout objet combustible comme les briqu
24. al before continuing in this section e If resistance values not close to the values given in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found After the problem has been located and repaired refer to the Sequence of Operation flow diagram in this section to test the power unit for proper operation Resistance Check 1 1 With the power disconnected set the ON OFF switch S1 to ON 2 Check resistance across input leads 3 Check resistance from input leads to ground 2 4 MO 2 4 gt J 2 4 A gt 20 Y powermax1000 Service Manual 3 7 MAINTENANCE Resistance Check 2 Check resistance across output diode bridge 3 8 powermax1000 Service Manual MAINTENANCE Troubleshooting Guide WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See warnings on page 3 7 before proceeding If no problems were found during the initial resistance checks and the power supply still does not operate correctly see the Troubleshooting Guide on the following pages Note The Troubleshooting Guide provides most probable causes and solutions Study the system wiring diagram and understand the theor
25. anifold ciens E rain rated rada rt nee rd nV Ya 4 3 123645 ee trente Work cable with clamp 15 ft 4 6 4 3 12869528 2 RG 4 3 1206D2 RE nn r ed enira 4 4 128665 22 24 Strain relief arc voltage 4 4 lPOWeFESWILCIS 4 4 128700 terere iir eret EMI Filter PCB CE 4 4 128666 ne car eere Power cable 20004 4 4 128705 0 Power cable 4 4 108627 ride 4 5 011093 Air filter element iii 4 5 011094 et coerente ta arr O FING filter DOW 4 5 128707470 eee Fan subassembly 4 5 1286925 n me ARE ee Male 4 5 12869015 er dese 4 5 12869325 ene Inductor lt lt 4 5 128694 Inductor output nnns 4 5 027662 A Thermal grease 5 oz 340 4 6 12867 ien tit
26. ard provides noise suppression and spike protection soft start is implemented the power board resistor and relay K1 The PFC Boost Converter consists of an isolated gate bipolar transistor IGBT Q7 choke and control circuit It provides a 750 VDC bus voltage when input AC voltage is between 170 and 540 VAC When the input voltage is above 540 VAC the bus voltage will rise to Vin v2 The inverter consists of an IGBT Q6 the power transformer T2 a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit and is rectified by the output diode The output circuitry consists of 2 current transfer sensors located on the power board the pilot arc IGBT Q8 and the output choke The control board s microprocessor monitors and regulates system operation and safety circuits The current is set to the desired value by adjusting the current adjustment knob The system compares the set point to the output current by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT Q6 The control board PCB3 includes a pilot arc control switch allowing the operator to turn the pilot arc ON useful when cutting expanded metal OFF for maximum life of consumables or increase the pilot arc to 20A useful for gouging or non transferred arc cutting powermax1000 Service Manual 3 3 MAINTENANCE Sequence of Operation System OFF lt
27. bels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION A signal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly Fire Prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosio
28. ccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PRECAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSEMENT sont situ es sur la machine pour signaler certains dangers sp cifiques Les messages d AVERTISSEMENT pr c dent les instructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas o ces instructions ne seraient pas suivies correctement Les messages de PR CAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque d tre endommag si les instructions ne sont pas suivies correctement Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur proximit loigner toute mati re inflammable une distance d au moins 10 m du poste de coupage Tremper le m tal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement A rer toute atmosph re potentiellement inflammable avant d utiliser un syst me plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par asp
29. ck only applies to 3 phase Check input voltage to the input diode bridge The AC voltage between any 2 input wires should equal the line voltage Line Voltage Y Line Voltage Line Voltage Y Y powermax1000 Service Manual 3 13 MAINTENANCE Voltage Check 2 Check output voltage of the input diode bridge Output VDC Line Voltage 1 414 Line Voltage 1 414 3 14 powermax1000 Service Manual MAINTENANCE Voltage Check 3 Check voltage across IGBT module Q7 750 VDC powermax1000 Service Manual 3 15 MAINTENANCE Voltage Check 4 Check voltage across IGBT module 06 750 VDC 375 VDC 375 VDC 3 16 powermax1000 Service Manual MAINTENANCE Voltage Check 5 Check voltage across power supply capacitors 375 VDC powermax1000 Service Manual 3 17 MAINTENANCE Component Replacement WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See warnings on page 3 7 before proceeding Power Cord Replacement Disconnect electrical power and gas supply before removing the old power
30. cord Installation See figures below 1 Insert the new power cord through the strain relief 2 Install the power cord connections where shown 3 Tighten the strain relief onto the power cord 4 Install the power supply cover 5 Reconnect electrical power and gas supply Black White Black Red White Green Green Single Phase Three Phase 3 18 powermax1000 Service Manual MAINTENANCE Torch Installation Turn power OFF 2 Remove power cord from power receptacle Open ETR door and route the lead through the end cap End Cap 50 powermax1000 Service Manual 3 19 MAINTENANCE 4 Align marks strain relief Quick Release Collar Slide quick release collar foward to lock in the gas fitting Make sure that the gas fitting is secure 7 Make sure that the red dot on the connector is on top then plug in the electrical connector Close ETR door 3 20 powermax1000 Service Manual Filter Element Replacement Disconnect electrical power and gas supply Remove filter bowl on new and old filte
31. damaged torch or lead assembly Verify fault control board PCB3 IF LED If Fault and IF LEDs are illuminated replace power board If IF LED is not illuminated replace torch and lead assembly NOTE OCV is 300VDC but is only available for 100 msec Measure at J15 and J16 using a Fluke 87 or equivalent digital multi meter AONVNALNIVIN enuen ooms 000 Problem This May Mean Cause Solution When pressing torch Worn consumables Worn out consumables Replace consumables trigger start switch pilot arc Improper air pressure starts but pops out before setting or low flow the normal 5 second time out period Insufficient supply or air leak on supply line Turn current adjust knob to test flow and set pressure regulator to 70 psi 4 7 bar for cutting or 50 psi 3 4 bar for gouging If unable to adjust to proper setting check external air supply Poor quality air Moisture or contaminates in air supply Add appropriate filtration and purge lines with nitrogen to flush out oil and moisture Insufficient input power Undersized electrical supply installation Breaker fuse Supply wire Verify external electrical power is installed per specifications in section 2 Check input voltage while trying to fire torch Voltage drop indicates undersized electrical supply installation Inverter fault or interlock Power board PCB2 failure If t
32. defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by ii 9 01 Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and Hypertherm s obligation to indemnify shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim LIMITATION OF LIABILITY In no event shall Hypertherm be liable to any person or entity for any incidental consequential indirect or punitive damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise and even if advised of the possibility of such damages LIABILITY CAP In no event shall Hypertherm s liability whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim INSURANCE At all times you will have and maintain insurance in such quantities and typ
33. drog ne lors du coupage de l aluminium 1a 2 Les chocs lectriques peuvent tre fatals sise 1a 3 Pr vention des chocs lectriques iii 1a 3 Le coupage peut produire des vapeurs 2 1a 3 plasma peut provoquer des blessures ou des 1 4 Torches allumage instantan eicere ice s ELE eau 1a 4 Les rayons de l arc peuvent br ler les yeux et la peau nennen entrent nnns 1a 4 Protection des yeux Protection de la peau Zone de coupage 1a 4 Mise alaimasse et la terre n hr dann as rera ee ander e N 1a 4 C ble de retour Table de travail 1a 4 2 etico ccena ett is en dns 1a 5 Les bouteilles de gaz comprim peuvent exploser en cas de dommages 1a 5 Le bruit peut provoquer des probl mes auditifs ir 1a 5 Pacemakers et proth ses auditives nennen entes 1 5 Un arc plasma peut endommager les tuyaux 1 5 MSC ed 1 6 powermax1000 Service Manual iii TABLE OF CONTENTS Section 2 Specificatio
34. e Ontario M9W 1R3 Canada 8 NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 10 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 11 98 SAFETY WARNING LABEL This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label WARNING Protect yourself and others Read and under stand this marking Disconnect power source before servicing Disconnect power source before disassembly of the torch Use torches specified in the instruction manual This plasma cutting machine must be connected to power source in accordance with applicable electrical codes Plasma arc cutting can be injurious to operator and persons in the work area Before operating read and understand the manufacturer s instruc tions and know your employer s safety practices AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Couper l alimentation avant d effectuer le d pann ge Couper l alimentation avant de d monter la torche Utiliser exclusivement les torches indiqu es dans le manual d ins
35. ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Become trained and read the instructions before working on the machine or cutting Do not remove or paint over cover warning labels Hypertherm Plasma Systems Section 1 SECURITE Dans cette section Identifier les consignes de s curit iii 1 2 Suivre les instructions de s curit iii 1 2 Danger Avertissement Pr cautions sise 1 2 Le coupage peut provoquer un incendie ou une 1 2 Pr vention des incendies Pr vention des explosions 1 2 Risque d explosion argon hydrog ne et m thane 1 2 D tonation de l hydrog ne lors du coupage de l aluminium essen 1 2 Les chocs lectriques peuvent tre fatals usine 1 3 Pr vention des chocs lectriques sisi 1 3 Le coupage peut produire des vapeurs toxiques 7 nena 1 3 L arc plasma peut provoquer des blessures ou des 1 4 Torches allumage instantan sisi 1 4 Les rayons de l arc peuvent br ler les yeux et la peau 1 4 Protection des yeux Protection de la peau Zone de coupage _ 1 4 Mise la masse et la terre oett ett ie te eret de epu ev d e net as ut 1 4 C ble de retour Table de travail Alimentation 444 1 4 S curit des bouteilles de ga
36. ement du syst me plasma ferme un circuit lectrique entre la torche et la pi ce a couper La pi ce font partie du circuit lectrique Ne jamais toucher le corps de la torche la pi ce couper ou l eau de la table eau pendant le fonctionnement du syst me plasma Pr vention des chocs lectriques Tous les syst mes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 400 V On doit prendre les pr cautions suivantes quand on utilise le syst me plasma Porter des bottes et des gants isolants et garder le corps et les v tements au sec Ne pas se tenir s asseoir ou se coucher sur une surface mouill e ni la toucher quand on utilise le systeme plasma S isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol S il s av re n cessaire de travailler dans ou pr s d un endroit humide proc der avec une extr me prudence Installer un sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence En cas d utilisation d une table eau s assurer que cette derni re est correctement mise la terre piece couper et tout autre l ment en contact avec cette LES CHOCS LECTRIQUES PEUVENT TRE FATALS Installer et mettre la terre l quipement selon les i
37. es and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products NATIONAL AND LOCAL CODES National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices TRANSFER OF RIGHTS You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Hypertherm Plasma Systems TABLE OF CONTENTS Electromagnetic 9 i ee ii Section1 Safety Recognize Safety MAO exec vat es 1 2 Follow Safety Instructions 1 2 Cutting Can Cause Fire OF EXplOSION dte b E a A eee arte 1 2 Electric Shock Cari 1 3 Cutting Produce Toxic Fum es iie acie er ete cea Eun ee E ka Ce Ed Ie ARE Ce deed 1
38. et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps Se former la technique du coupage et lire les instructions avant de manipuler l quipement ou de proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit Hypertherm Systemes plasma Section 2 SPECIFICATIONS In this section Specifications Power Supply aii deese ed ate teste date A eee a teeta 2 2 Power Supply Dimensions and Weight sisi 2 3 Specifications T60 TOrGlI6S a id o aug Dv o a RR RV RE ND ER IR vacation E E a 2 4 MONCH DIMENSIONS IQ UTILIS 2 5 Symbols and MAKING S E 2 6 powermax1000 Service Manual 2 1 SPECIFICATIONS Specifications Power Supply Voltage U2 Rated Open Circuit Voltage 300 VDC OutputCharacteristic Drooping Defined as a plot of output voltage versus output current Rated Output Current 15 20 60 Hypertherm Standard Rated Output 140 VDC Power Factor Duty Cycle X at 104 F 40 C at Volts AC rms X rated conditions U41 11 U2 12 200 208 VAC 1PH 40 230 240 VAC 1PH 50 Ton Tbase 480 VAC 1PH 50 Ton time minutes 200 208 VAC 3PH 40 Tbase 10 minutes 230 240 VAC 3PH 50 380 400 415 VAC 3PH 50 480 VAC 3PH 50 600 VAC 3PH 50 Operatin
39. ets au butane ou les allumettes Zone de coupage Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la lumi re ultraviolette Peindre les murs et autres surfaces de couleur sombre pour r duire la r flexion de la lumi re Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder l arc Utiliser des affiches ou des panneaux MISE LA MASSE ET LA TERRE Cable de retour Bien fixer le cable de retour ou de masse la pi ce couper ou la table de travail de facon assurer un bon contact m tal m tal Ne pas fixer le c ble de retour la partie de la pi ce qui doit se d tacher Table de travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s Alimentation S assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret du sectionneur S il est n cessaire de brancher le cordon d alimentation la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bien serrer l crou de retenue S assurer que toutes les connexions sont bien serr e
40. eve Replacement Kit T60M T80M Mounting Kit powermax1000 Service Manual 5 7 In this section Electrical Schematic powermax1000 Service Manual nnne m m iti Section 6 WIRING DIAGRAMS PFC CHOKE POWER BD PCB2 1 DOMESTIC UNIT yi oni 1 LT SOFT START 1 5 I coro ri E ote i d 1 1 p s ote power T i Lo 44 TRANSFORMER gy E DESI mi some Lo sun m 1 suey Lo cour x ss er ne oe ee 3 Liner 1 1 1 1 o 2 opal 1 in 1 a o L y Le ae EEE ES D E E 1 CEUNIT 1 T 1 1 1 1 t co 1 1 MET Je 1 1 FILTER 1 MTG 4 1 aw oto vcn 1 1 MES ote 1 1 o ES 2 lo sn DO ES
41. g temperature 14 to 104 F 10 to 40 C Rated AC phases PH and line frequency Hz PH Hz Standard Model 1 3 50 60 CE Model 3 50 60 Rated Input Voltage U1 rated Input Volts AC rms l1 Amps rms Current 14 and at rated Output 200 208 VAC 1PH 50 32 Ue and l2 cutting only 230 240 VAC 1PH 44 31 480 VAC 1PH 22 15 5 200 208 VAC 3PH 30 19 l1eff 14 used to determine 230 240 VAC 3PH 26 18 rating of power cord 380 400 415 VAC 3PH 15 10 5 480 VAC 3PH 12 8 5 600 VAC 3PH 11 8 Ui Volts AC rms Harmonic Power Factor Displacement Power Factor 200 208 VAC 1PH 0 99 0 99 230 240 VAC 1PH 0 99 0 99 480 VAC 1PH 0 91 0 99 200 208 VAC 3PH 0 94 0 99 230 240 VAC 3PH 0 94 0 99 380 400 415 VAC 3PH 0 94 0 99 480 VAC 3PH 0 94 0 99 600 VAC 3PH 0 80 0 99 Short Circuit Ratio CE Model only Volts AC rms 3PH Rsce 400 VAC 153 230 VAC 97 This equipment conforms to IEC 61000 3 12 provided that Rsce min 153 at 400VAC 97 at 230 VAC 3PH IP code Degree of protection provided by enclosure IP23CS IP International Protection 2 No ingress foreign objects 212 5mm 0 5 in 3 No harmful ingress spraying water C line circuits protected against ingress of tool 22 5 mm dia x 100 mm long 0 1 inch x 4 0 inch S fan stationary during water test WARNING DO NOT OPERATE IN RAIN Toppling Tilting with or wi
42. he control board PCB2 IF LED illuminates and one or more of the fault LEDs illuminate then the fault is caused by the parameter monitored by the fault LED If no fault LED is illuminated replace power board Machine will not cut material Inadequate ground does not appear to be Operating at full cutting power Poor work lead connection Damaged work lead Verify work lead is attached to workpiece and workpiece is free of rust paint etc Check continuity of work lead Replace or repair as required Defective pilot arc IGBT 08 Turn power OFF remove consumables check resistance between plunger and work piece If resistance is greater than 8k ohms Inspect work lead Check pilot arc IGBT resistance between two screws at Q8 on power board If resistance is less than 5k ohms replace pilot arc IGBT Low output from power supply Losing pilot arc when going Continous pilot arc does off plate while in continuous work pilot mode Current adjustment set too low Verify current adjust knob is at proper setting turn to max full clockwise Defective power board current sensor Mode switch set wrong Replace power board Can confirm power output by measuring with a DC current clamp meter on work lead Set mode switch to correct position Faulty control board PCB3 Replace control board AONVNALNIVIN MAINTENANCE Voltage Checks Voltage Check 1 This voltage che
43. in Body Replacement Retaining Clip O ring Cap off Sensor Replacement Cap off Sensor screws T60 T60M Torch Head Repair Kit Handle Kit Handle screws Safety Trigger Spring 25 ft 7 6 m Torch Lead Replacement 50 ft 15 2 m Torch Lead Replacement ETR Repair Kit Regional Repair Centers only Start Switch Quantity a ON cb mi assembly includes the following consumables See page 4 3 for details of consumable parts 120926 120925 120928 120929 120931 Electrode Swirl Ring Retaining Cap Shield Nozzle o e powermax1000 Service Manual PARTS TORCH AND CONSUMABLES powermax1000 Service Manual 5 3 PARTS TORCH AND CONSUMABLES T60M Machine Torch Assembly Item O1 BR D Part Number 083175 083174 083176 083177 128640 027889 058519 128639 075571 128521 128643 075004 128710 128634 128633 128635 128641 128638 128645 Description T60M Machine Torch Assembly with 15 ft 4 6 m Lead T60M Machine Torch Assembly with 25 ft 7 6 m Lead T60M Machine Torch Assembly with 35 ft 10 7 m Lead T60M Machine Torch Assembly with 50 ft 15 2 m Lead T60M Torch Main Body Replacement Kit Retaining Clip O ring Cap off Sensor Replacement Kit Cap off Sensor Screws T60 T60M Torch Head Repair Kit Torch Mounting Sleeve Replacement Kit Torch Mounting Screws Torch Positioning Sleeve 15 ft 4 6 m Torch Lead Replacement Kit 25 ft 7 6 m Torch
44. iration est n cessaire Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT Risque d explosion argon hydrog ne et m thane L hydrog ne et le m thane sont des gaz inflammables et potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la pi ce d aluminium de l hydrog ne libre peut s accumuler sous la pi ce couper et d tonner lors du coupage plasma Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrog ne Se r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration 1a 2 2 12 01 Hypertherm Systemes plasma SECURITE Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal ou des brdlures graves La mise en fonctionn
45. ith a DC digital voltage meter Voltage should be approximately 3 3V when regulator is set at 70 psi Change regulator setting and verify that voltage also changes Replace air filter element AONVNALNIVIN ienuew oms 000 LL Problem This May Mean Cause Solution Yellow cap sensing LED illuminates s Safety circuit not satisfied Consumables not installed installed improperly or Damage to safety circuit damaged Refer to consumable diagram for proper installation Try new consumables Remove torch Check torch end of connector Install consumables and check continuity on J18 pins 11 and 12 orange and blue wires If open circuit inspect torch Over temp LED illuminates Ti Temperature sensors not satisfied Exceeded duty cycle Allow unit to cool Stay with duty cycle limits in manual Fan not operating or improperly operatin Defective heatsink temperature switch TP1 check when system is cool at least 15 min after use Disconnect J2 and jump pins 1 and 2 Fan should operate Remove J2 from power board PCB2 Check temperature PCB PCB4 by checking resistance on pins 1 and 2 If resistance is not between 3k 5k ohms replace temperature sensor PCB PCB4 Defective power transformer T2 temperature sensor TS2 check when system is cool at least 60 min after use Check transformer sensor T2 by checking resistance on J21 pins 1 and 2 on wi
46. itor to PC board Remove fan assembly Remove capacitor from fan side of power supply Installation Refer to figure below Align bleeder hole on capacitor with view hole on power board Install new capacitor and secure with 2 screws Tighten screws to 20 inch pounds 24 kg cm AP Install the power supply cover ki SN 5 i AY i SN Remove and install screws from power board side Remove and install Correct Installation capacitors from fan side powermax1000 Service Manual 3 23 MAINTENANCE Heat Sink Component Replacement Installation e Install components to the heat sink as shown below e Use new thermal pads on temperature sensor Use thermal grease on all components Apply a thin coat to the component install with screws and tighten to required torque Re torque after 2 minutes Repeat until torque is maintained Clean excess grease from heat sink Thermal Grease Notes 1 Apply thermal grease and torque to 8 9 kg cm 2 Apply thermal grease and torque to 20 23 kg cm 3 Apply thermal grease and torque to 35 40 kg cm 3 24 powermax1000 Service Manual Section 4 PARTS LIST POWER SUPPLY In this section qne eee 4 2 Interior
47. l compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national or local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma system Warn others nearby about the noise hazard A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch e PACEMAKER AND HEARING AID OPERATION Pacemaker and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field haza
48. l est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste correspondent aux num ros des images AVERTISSEMENT Pour votre protection et celle des autres lire et comprendre ces consignes Couper l alimentation avant d effectuer le d pann ge Couper l alimentation avant de d monter la torche Utiliser exclusivement les torches indiqu es dans le manual d instructions Le raccordement au r seau de cette machine de coupage arc plasma doit tre comforme aux codes de l lectricit pertinents Le coupage arc plasma comporte des risques pour l utilisateur et les personnes se trouvant dans la zone de travail Avant le coupage lire et comprendre les instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise your breathing zone and the general area f ventilation is inadequate use an approved respirator WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known WARNING Protect yourself and others Read and under stand this marking Disconnect power source before servicing Disconnect power source before disassembly of the torch Use torches specified in the instruction manual This plasma cutting machine must be connected to power source in accordance with applicable electrical codes Plasma arc cutting can be injurious to operator and persons
49. lding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer Hypertherm Plasma Systems 1 3 8 99 SAFETY Instant On Torches Plasma arc comes on immediately when the torch switch is activated PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc will cut quickly through gloves and skin Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others Eye Protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national or local codes Wear eye protection safety glasses or goggles with side shields or a welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Lens Shade Arc Current AWS USA ISO 4850 Up to 100A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Over 400 A No 14 No 14 ARC RAYS CAN BURN EYES AND SKIN Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Cuffless trousers to prevent entry of sparks and slag Remove any combustibles such as a butane lighter or ma
50. n Prevention Do not use the plasma system if explosive dust vapors may be present Do not cut pressurized cylinders pipes or any closed container Do not cut containers that have held combustible materials CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation Refer to the Appendix section of this manual for aeration manifold details WARNING Hydrogen Detonation with Aluminum Cutting 1 2 11 98 Hypertherm Plasma Systems SAFETY Touching live electrical parts can cause a fatal shock or severe burn Operating the plasma system completes electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Elec
51. n injure eyes and burn skin Wear correct eye and body protection Pilot arc can cause burns Keep the torch nozzle away from yourself and others when the switch is depressed Wear correct eye and body protection NE PAS ENLEVER CET AVIS AVERTISSEMENT AMORCAGE INSTANTAN L arc s amorce aussit t qu on enclenche l interrupteur de la torche Noise can damage hearing Wear correct ear protection A DO NOT REMOVE THIS MARKING WARNING INSTANT START Arc starts instantly after torch switch is depressed 8 99 1 1 1 2 Cutting sparks can cause explosion or fire Keep flammables away from cutting Keep a fire extinguisher nearby and have a watchperson ready to use it Do not cut on any closed containers The plasma arc can cause injury and burns Turn off power before disassembling torch Do not hold the material near cutting path Wear complete body protection Electric shock from torch or wiring can kill Protect yourself from electric shock Wear insulating gloves Do not wear wet or damaged gloves Insulate yourself from work and ground Disconnect input plug or power before working on machine Breathing cutting fumes can be hazardous to your health Keep your head out of the fumes Use forced ventilation or local exhaust to remove the fumes Use ventilating fan to remove the fumes Arc rays can burn eyes and injure skin Wear hat and safety glasses Use
52. ns Specifications Power Supply eter i Le EFE Yd atc Ee ann ets 2 2 Power Supply Dimensions Weight cen iiiter certe rude tbe ete ken puru ea ete gas equipe inertie 2 3 Specifications T60 TOrcli8S esito Ere xn t Depas 2 4 a a S 2 5 Marking S er 2 6 Section 3 Maintenance Controls and Mdi ss in Mein nent en a en A te an tnt tite 3 2 Theory Of Operation er tend een 3 3 Generals ssns aai eia E LI 3 3 Funcional 2777 3 3 S quence Of OPSratlOn EE 3 4 Troubleshooting 3 5 Cet 3 5 Troubleshooting Procedures and Sequence 3 5 Visual Inspection External a an nn ta 3 5 Visual Inspection Internal 3 6 R SISTANCE CHECKS ASE 3 7 Troubleshooting Guide sise 3 9 Voltage A 3 13 Component 3 18 Power Cord RE placement ics posse edu lua gang cx dx XR 3 18 Torch
53. nstructions du pr sent manuel et conform ment aux codes lectriques locaux et nationaux Inspecter fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer les c bles de la torche qui sont us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du coupage Laisser la pi ce couper en place ou sur la table de travail le c ble de retour connect lors du coupage Avant de v rifier de nettoyer ou de remplacer les pi ces de la torche couper l alimentation ou d brancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de s curit Avant d enlever le capot du syst me ou de la source de courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le syst me plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas utiliser des torches inappropri es qui pourraient surchauffer et pr senter des risques pour la s curit coupage peut prod
54. or and measure for VDC on power board 1 J4 Pin16 5 VDC J4 Pin18 5 VDC with start switch depressed If incorrect voltage or no voltage replace power board If voltage is correct replace control board Replace boost IGBT Q7 and inspect power board PCB2 for damage Power LED illuminates and air flows from torch torch trigger start switch not pressed Voltage LED illuminates System is in gas test mode Current adjustment knob is in gas test position Turn knob clockwise until above the 20 amp setting Solenoid valve V1 stuck open Faulty valve Disconnect J20 from power board PCB2 If air flow continues replace valve V1 Defective power board PCB2 Improper line voltage Constant voltage supplied to valve Voltage below proper operating limits or loss of phase Disconnect J20 from power board PCB2 If air flow Verify incoming line voltage Air pressure LED blinks yellow Insufficient air pressure No air supplied to unit Connect air supply Air pressure below operating requirement Turn current adjustment knob to gas test and set pressure to 70 psi 4 8 bar for cutting and 50 3 4 bar for gouging is required for system operation Check that the inlet gas pressure is within setup specifications in section 2 Faulty pressure sensor assembly Dirty air filter element With normal air supply gt 90 psi connected measure R50 left to TP1 w
55. or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death Keep the cutting area well ventilated or use an approved air supplied respirator Do not cut in locations near degreasing cleaning or spraying operations The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation Do not cut metal coated or containing toxic materi als such as zinc galvanized lead cadmium or e CUTTING CAN PRODUCE TOXIC FUMES beryllium unless the area is well ventilated and the operator wears an air supplied respirator The coatings and any metals containing these elements can produce toxic fumes when cut Never cut containers with potentially toxic materials inside they must be emptied and properly cleaned first This product when used for we
56. ould be considered However metallic compo nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic compo nents and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equip ment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be au thorized by a person who is competent to assess whether the changes will increase the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC TC26 sec 94 and IEC TC26 108A CD Arc Welding Equipment Installation and Use
57. powermax1000 Plasma Arc Cutting System Service Manual 804300 Revision 0 a De m manens The world leader in plasma cutting technology powermaxtooo Service Manual P N 804300 Revision 0 December 2001 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2001 Hypertherm Inc All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries 7 13 01 Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments 800 643 9878 Tel Technical Service 800 737 2978 Tel Customer Service Hypertherm Automation 5 Technology Drive West Lebanon NH 03755 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher C haussee 6 63457 Hanau W olfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm Singapore Pte Ltd No 19 Kaki Bukit Road 2 K B Warehouse C omplex Singapore 417847 Republic of Singapore 65 841 2489 Tel 65 841 2490 Fax 65 841 2489 Technical Service Japan 1952 14 Yata Natsumegi Mishima City Shizuoka Pref 411 0801 Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax Hypertherm UK Ltd 9 Berkeley Court Manor Park Runcorn Cheshire England WA7 1TQ 44 1928 579 074 Tel 44 1928 579 604 Fax
58. r A Pull down black release tab and hold B Rotate filter bowl until it is released C Pull filter bowl down to remove Do not discard the O ring Remove the filter element from the filter housing NOTE Do not allow the filter element to turn when loosening the screw Install filter bowl A Slide filter bowl over filter element B Align marks on filter bow and filter body C Rotate filter bowl until it locks in place powermax1000 Service Manual MAINTENANCE 3 21 MAINTENANCE Work Cable Replacement Disconnect electrical power gas supply and torch lead before removing the old work cable Installation Refer to figure below 1 2 Install the strain relief to the power supply and secure with nut Tighten the strain relief collar onto the cable Connect the work cable to the power board at J14 Tighten nut to 10 in Ib 12 kg cm of torque Install ETR barrier Install the power supply cover CAUTION This is a high current connection Proper torque is critical Connect to J14 Strain Relief 3 22 ETR Barrier d WA Vs powermax1000 Service Manual MAINTENANCE Capacitor Replacement Removal Refer to figure below Disconnect electrical power and gas supply before removing the power supply cover Remove screws securing capac
59. r le robinet des bouteilles LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du syst me plasma Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELES Les tuyaux gel s peuvent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma AS Les champs magn tiques produits par les courants haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant de s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin de soi et du m me c t du corps le c ble de Faire passer le faisceau de la torche le plus pr s possible Ne pas s enrouler le faisceau de la torche ou le c ble de Se tenir le plus loin possible de la source de courant PACEMAKERS PROTHESES AUDITIVES retour le faisceau la torche du c ble de retour retour autour du corps Hypertherm Syst mes plasma 1 5 2 12 01 SECURITE Etiquette de s curit Cette tiquette est affich e sur la source de courant I
60. rds Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible ADDITIONAL SAFETY INFORMATION 1 ANSI Standard Z49 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 ANSI Standard 749 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 Hypertherm Plasma Systems 5 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 7 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdal
61. res If greater than 15 k ohms replace power transformer Power LED illuminates all fault LEDs extinguished but no air flow or firing of torch when torch switch is pressed Start signal not being received by power supply Start LED off on control board PCB3 Damage to torch and lead assembly Remove torch Check J18 pins 10 and 12 violet and orange wires for continuity when torch trigger is depressed If open circuit inspect torch and lead assembly Solenoid valve not working Valve stuck or no voltage to valve Check voltage at valve Remove connector J21 from valve turn current adjust knob to test flow and check for 24 VDC at connector J21 pins 1 and 3 If no voltage replace power board If voltage clear air lines or replace valve Damaged torch or lead Torch plunger stuck open or Verify fault control board PCB3 TSO LED illuminated assembly broken torch leads Inspect torch and lead assembly Damaged control board Defective control board Replace board PCB3 When pressing torch Worn or bad Overuse or improperly installed Replace consumables trigger start switch air flows from torch but no arc consumables consumables Insufficient air flow Improper pressure setting Turn current adjustment knob to test flow and set pressure regulator 70 psi 4 7 bar for cutting and 50 psi 3 4 bar for gouging No output from power board PCB2 Power board failure or
62. s pour viter la surchauffe 1a 4 2 12 01 Hypertherm Systemes plasma SECURITE SECURITE DES BOUTEILLES DE GAZ COMPRIME Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles r gulateurs tuyaux et accessoires appropri s et 5 pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur Les bouteilles de gaz contiennent du gaz haute pression Si une bouteille est endommag e elle peut exploser LES BOUTEILLES DE GAZ COMPRIME PEUVENT EXPLOSER EN CAS DE DOMMAGES Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux Ne jamais utiliser une bouteille qui n est pas plac e la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloque
63. s complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from either board To do so will risk a short circuit between the AC input circuit and the output circuit and may result serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards Visual Inspection Internal 1 Set the ON OFF switch S1 to O OFF unplug the power cord and disconnect the gas supply 2 Remove the cover of the power supply by removing the 12 securing screws 3 Inspect the inside of the power supply especially on the side with the power board Look for broken or loose wiring connections burn and char marks damaged components etc Repair or replace as necessary 3 6 powermax1000 Service Manual MAINTENANCE Resistance Checks All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform Visual Inspection Intern
64. t Sink Assembly AA Part Item Number Description Designator Qty 027662 Thermal grease 5 oz DC 340 1 1 128677 Output diode bridge 1 2 128697 IGBT inverter Q6 1 3 128700 Temperature Switch PCB4 1 4 128708 IGBT PFC Q7 1 5 128696 Input diode bridge D24 1 6 128670 Snubber resister 1 7 128699 IGBT pilot arc 1 8 128669 Snubber resister 1 Reference page 3 24 for torque specifications 4 6 powermax1000 Service Manual PARTS POWER SUPPLY Recommended Spare Parts Powermax1000 Part Description Reference 128689 55 ea ee Front end panel 4 2 128687 Front end panel 7 4 2 1286206 otii eei es Rear end pariel oie seek exped ec cav ad 4 2 008965 eet en Current adjustment knob 4 2 128686 Labels DOmestie LL 4 2 128685 50 Pc 4 2 128690 cedit eiie Power supply cover Domestic apices 4 2 128688 ean nada Power supply cover 4 2 ZG LOA Control PCB assembly Domestic 4 3 1287089 recte reete Control PCB assembly 4 3 128623 inedite nes Pressure regulator cicero eec aud anses 4 3 128622 GAS m
65. tches from your pockets before cutting Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work Table Connect the work table to an earth ground in accordance with appropriate national or local electrical codes Input Power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be sure to connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating e e e 1 4 4 99 Hypertherm Plasma Systems SAFETY COMPRESSED GAS EQUIPMENT SAFETY Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain al
66. thout wheel kit Up to 150 incline Gas Type Air Nitrogen Gas Quality Clean moisture free oil free Gas Inlet Pressure and Flow See Section 3 Setup 2 2 powermax1000 Service Manual Power Supply Dimensions and Weight Weight of power supply without torch powermax1000 Service Manual La 23in __ 584 SPECIFICATIONS 5 10 5 in sae 267 mm 19 5 495 SPECIFICATIONS Specifications T60 Torches Cutting Capacity At 60 Amps Recommended capacity 3 4 inch 19 mm Maximum capacity 1 inch 25 mm Severance capacity 1 1 4 inch 32 mm Gouging Capability metal removal rate on mild steel 10 0 pounds 4 5 kg hour Weight T60 6 9 pounds 3 1 kg with 25 ft 7 5 m lead 13 6 pounds 6 2 kg with 50 ft 15 m lead T60M 4 5 pounds 2 0 kg with 15 ft 4 5 m lead 8 3 pounds 3 8 kg with 25 ft 7 5 m lead 9 9 pounds 4 5 kg with 35 ft 10 7 m lead 15 0 pounds 6 8 kg with 50 ft 15 m lead powermax1000 Service Manual SPECIFICATIONS Torch Dimensions T60 Hand Torch Dimensions T60M Machine Torch Dimensions 15 06 383 mm y 00 1 38 35 203 32 pitch 125 3 2 mm width powermax1000 Service Manual 2 5 SPECIFICATIONS Symbols and Markings S
67. tric Shock Prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and keep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground ELECTRIC SHOCK CAN KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass
68. tructions Le raccordement au r seau de cette machine de coupage arc plasma doit tre comforme aux codes de l lectricit pertinents Le coupage arc plasma comporte des risques pour l utilisateur et les personnes se trouvant dans la zone de travail Avant le coupage lire et comprendre les instructions du fabricant Appliquer galement les consignes de s curit de votre entreprise f ventilation is inadequate use an approved respirator WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known Electric shock can kill Do not touch live electrical parts Keep all panels and covers in place when the machine is connected to a power source Insulate yourself from work and ground wear insulating gloves shoes and Clothing Keep gloves shoes clothing work area torch and this machinery dry Fumes and gases can injure your health Keep your head out of the fumes Provide ventilation exhaust at the arc or both to keep the fumes and gases from your breathing zone and the general area to the state of California to cause birth defects and in some cases cancer Heat splatter and sparks cause fire and burns Do not cut near combustible material Do not cut containers that have held combustibles Do not have on your person any combustibles such as a butane lighter or matches Explosion will result if pressurized containers are cut Arc rays ca
69. uire des vapeurs et des gaz toxiques qui r duisent le niveau dans l air et peuvent provoquer des blessures voire la mort Conserver le poste de coupage bien a r ou utiliser un masque respiratoire homologu Ne pas proc der au coupage pr s d endroits s effectuent le d graissage le nettoyage ou vapori sation Certains solvants chlor s se d composent sous l effet des rayons ultraviolets et forment du phosg ne Ne pas couper des m taux peints ou contenant des mati res toxiques comme le zinc galvanis le plomb le cadmium ou le b ryllium moins que la zone de travail LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES soit tr s bien ventil e et que l op rateur porte un masque respiratoire Les rev tements et m taux contenant ces mati res peuvent produire des vapeurs toxiques lors du coupage Ne jamais couper de r cipients pouvant contenir des mati res inflammables avant de les avoir vid s et nettoy s correctement Quand on utilise ce produit pour le soudage ou le coupage il d gage des fum es et des gaz qui contiennent des produits chimiques qui selon l tat de Californie provoquent des anomalies cong nitales et dans certains cas le cancer Hypertherm Systemes plasma 1a 3 2 12 01 SECURITE V Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche Soit mise en marche L ARC PLASMA PEUT PROVOQUER DES BLES
70. us nette Output diode bridge 4 6 120697 PE IGBT ae a P 4 6 128700 eee ees gines e 4 6 128708 xiii eee terea IGBI PEC waisted ashes HX 4 6 1286965 eicit this Input diode bridge 4 6 1286 0 ne Ra Snubber resister sie serica nra T teste 4 6 128699 EAE S EE i e PAAA A AE N 4 6 286695 anan ganna Snubber resister 4 6 powermax1000 Service Manual 4 7 Section 5 PARTS LIST TORCH AND CONSUMABLES In this section 160 E 5 2 T60M Machine Torch Assembly ss 5 4 Torch Gonsumable Configurations near tit ner 5 6 Recommended Spare 5 7 powermax1000 Service Manual 5 1 PARTS TORCH AND CONSUMABLES T60 Hand Torch Assembly Item ND Part Number 083172 083171 128564 027889 058519 128639 075571 128521 128644 075586 002244 027254 128681 128682 128638 128642 Description T60 Hand Torch Assembly with 25 ft 7 6 m Lead T60 Hand Torch Assembly with 50 ft 15 2 m Lead T60 Torch Ma
71. y of operation before troubleshooting Before purchasing a major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility powermax1000 Service Manual 3 9 OL ienuew ooms 000 Problem This May Mean Cause Solution Turn power switch ON and Power On LED does not illuminate Red LED on power board PCB2 illuminates when input voltage is between 200 540 VAC Insufficient voltage to control circuits or shorted power component No voltage or improper voltage applied to unit Verify incoming voltage is between 200 600 VAC Defective power switch S1 Measure AC voltage at bottom terminals of switch If no voltage replace switch Defective filter board PCB1 CE System only Measure AC voltage at input diode bridge If no voltage or low voltage replace filter board Defective input diode bridge D24 Measure DC voltage on input diode bridge Voltage at input diode bridge should be approximately Vin V2 If incorrect voltage or no voltage replace input diode bridge Defective power board PCB2 or IGBT module Q7 Bus voltage should be 750 VDC when input voltage is between 200 540 VAC If voltage is incorrect inspect power board and IGBT module for damage Defective power board PCB2 or control board PCB3 Defective boost IGBT module Q7 or power board PCB2 Disconnect power board J4 connect
72. z comprim sise 1 5 Les bouteilles de gaz comprim peuvent exploser en cas de dommages 1 5 Le bruit peut provoquer des probl mes auditifs 1 5 Pacemakers et proth ses auditives 1 5 Un arc plasma peut endommager les tuyaux gel s 1 5 EtiquettedieSaculld en o hr to M ate eu 1 6 Hypertherm Systemes plasma 1 1 2 12 01 SECURITE IDENTIFIER LES CONSIGNES A DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre faire fonctionner la machine et utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et ra

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